NitroDann's Long Awaited Garage Thread

Postby **NitroDann** » Mon Feb 11, 2013 11:03 pm

I say just put a huge one on, if you can lose your arm in it and its straight through it wont affect flow more than 2 or 3 HP.

What you cannot see in that pic is that it isnt just a tab it has another piece welded on at 90* on the exhaust pipe side, so does the rear muffler brace.

People will be able to give an indication of how loud this is on the track soon enough to help you decide.

When you say extend the hangers you mean hammer them around the pipe?
So far so good with triangulated hangers.

Dann

tinsfci · Postby **tinsfci** » Mon Feb 11, 2013 11:29 pm

Forming a hook by bashing it around something the same diameter as the pipe would be better, adding a circular doubler plate on the pipe (so the weld on the pipe has no "end") then welding the bracket onto the doubler plate would be better again but probably overkill.

If the current bracket is an "L" shape as it butts onto the pipe then the two ends are the most likely place it will crack from fatigue and heat due to the relatively sharp section of the weld. What ever you do, try to mechanically support the pipe as much as possible to make it easier for the weld, and try to make the radius of the weld as large as possible to avoid stress raisers.

My day job involves messing about with rail mounted mine equipment that can weigh up to 1500 tonnes, welding brackets directly to primary structure instead of a circular double plate is a crucifiction offence, the main offenders are sparkies!

Postby **NitroDann** » Mon Feb 11, 2013 11:34 pm

Define circular double plate. I totally get bending the hanger into a curve. Need to work out a good way to do it because I use 12mm rod not 8mm like factory.

Dann

Postby **NitroDann** » Mon Feb 11, 2013 11:37 pm

You know I used to only grind the bar curved so I could get a longer weld onto it but I've pulled enough aftermarket exhausts off now to see that doing that alone isn't good enough to last say 5 or more years every time, which is why I have moved to adding the second bar to triangulate it.

90 percent of custom jobs I've seen don't even grind the rod or use thicker rod, even those coming from well known places within this community.

Dann

tinsfci · Postby **tinsfci** » Mon Feb 11, 2013 11:54 pm

Doubler plate= grab a 50mm hole saw and drill through the side of a piece of scrap pipe of the same diameter as the exhaust. The curved disc inside the hole saw is the douber plate.

Weld the plate onto the exhaust, there are now no sharp edges of welds directly on the constantly expanding and contracting exhaust. No sharp changes in weld profile means less chance of a crack forming as it will usually happen where there is a sharp edge or undercut, or porosity etc.

Weld bracket onto the doubler plate following similar rules of no sharp edges if you possibly can, again so you dont have a stress concentration point. If a crack does form on the doubler plate you have not compromised your exhaust and it will be easier to weld up.

I'll stress that I have never seen anyone bother to do this on an exhaust, but F* it. Why follow what every one else does!

Another way to do it would be to use an inch of off cut pipe and split it so you can wrap it around the exhaust, then weld the bracket to that. The more you spread the load, the less likely it will crack.

Now back to the man cave with you, I expect to see photos of a dead sexy exhaust hanger by morning

Postby **NitroDann** » Tue Feb 12, 2013 12:01 am

I'll do one for shits and gigs ok. Tomorrow if I get the car started and have a spare half hour.

Dann

tinsfci · Postby **tinsfci** » Tue Feb 12, 2013 12:10 am

Looking forward to seeing what you come up with.

Postby **NitroDann** » Tue Feb 12, 2013 8:00 pm

Heres today's work.

Only Trackspeeds best. Everything is milled and gasket free.

Getting the water and oil lines sorted, its has oil lines that are 2 layer, with the outside being a heat resistant silicone, then it has heat wrap that is the fibreglass on the inside, some super high temp polymer on the outside kind.

Heres just a bunch of pics of the completed setup.

Built a wastegate bracket from stainless, I was going to weld alloy bosses onto the turbo but got lazy.

Just a couple to show just how tucked up that exhaust actually is.

So anyways, I gave it back to him this arvo.

It starts, it runs, its goes, Zoooooo-TUTUTUTUTUTUTUTooo when you rev it. All the good stuff you know.

Im very happy with how the water lines, the brace and the oil feed interact.
not sure how it translates into photos but in person its very neat.

Couple of bits to do still, TPS for MS2's EBC, fix the bov /IWG vacuum tubes etc, but it should hit the dyno this week or next.

Im waiting for a single flange for a manifold and the only other thing then is the BIG FAT BORG!

Dann